Method of securing an insert to a sheet metal body



Sept. 5, 19.67 v w. E. WALTON ETAL 3,339,270

METHOD OF SECURING AN INSERT TO A SHEET METAL BODY Filed Sept. 18, 1964 2 Sheets-Sheet l INVENTORS l V/L new 5 ML ro/v &

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ATTORNEY Sept 5, 1967 W. E. WALTON ETAL METHOD OF SECURING AN INSERT TO A SHEET METAL BODY Filed Sept. 18, 1964 2 Sheets-Sheet 2 7 M77 7a" 5%) a0 INVENTORS W/L F/PED 5. W44 7011/ 84 BY ALEX 0. 600/900 United States Patent 3,339,270 METHOD OF SECURING AN INSERT TO A SHEET METAL BODY Wilfred E. Walton, Sylvania, and Alex D. Bourdo, Toledo, Ohio, assignors to Universal American Corporation, New York, N.Y., a corporation of Delaware Filed Sept. 18, 1964, Ser. No. 397,535 8 Claims. (Cl. 29-511) ABSTRACT 0F THE DISCLQSURE The present invention pertains to a method of forming or shaping a region of a sheet of metal to a dished configuration and distorting metal of the dished configuration into embracing relation with an insert to permanently anchor the insert to the sheet metal body.

This invention relates to a method of forming a body or member of sheet metal to embrace an insert or inserts to anchor or secure the inserts permanently to the sheet metal body.

Heretofore it has been a practice in fabricating housings, casings or closure constructions and the like to fashion the housing, casing or the like of cast metal such as cast iron, and machine bores in boss portions of the cast metal bodies to receive and provide bearings for shafts, or to receive bearing bushings or inserts for other similar purposes. The installation of inserts in cast metal bodies has been comparatively expensive by reason of the accurate machine work required to press or otherwise securely anchor solid metal inserts in bores or recesses in cast metal bodies.

The present invention has for an object the provision of a method of forming or shaping a sheet of metal in a manner to embrace a solid preformed insert or member whereby the insert or member is permanently anchored or fixed to the sheet metal body by snug interlocking engagement of the sheet metal with the insert or member.

An object of the invention resides in the provision of a method in which a preformedinsert or plurality of inserts are utilized as a male portion or portions of die means of a character operable to shape and conform a sheet of metal into interengaging and interlocking relation with the insert or inserts whereby the same are permanently anchored in the conformed sheet metal body without the use of extraneous securing or anchoring means.

Another object of the invention resides in a method in which a plurality of preformed inserts are fixedly anchored to the sheet metal body by conforming the sheet metal to the shape of the inserts and embracing the inserts by the sheet metal in a manner whereby the relative positions of the inserts may be maintained with a high degree of accuracy.

Another object of the invention resides in a method of drawing or conforming metal of a sheet into interengaging relation with one or more preformed solid inserts whereby the metal of the sheet is forced or cold flowed into recesses or indentations provided in the inserts whereby the inserts are permanently anchored or assembled with the body of sheet metal.

Another object of the invention resides in the provision of a method of assembling preformed inserts of muchcular cross section in a sheet metal body .by drawing, shaping or conforming the sheet metal to the configuration of the insert to prevent dislodgment of the insert.

Another object of the invention resides in a method of shaping and drawing metal of a sheet to embrace an insert wherein the insert may be accurately positioned and the metal of the sheet interlocked with a recessed configuration or indentations fashioned in the insert to prevent relative movement of the insert with respect to the sheet metal body.

Further objects and advantages are within the scope of this invention such as relate to the arrangement, operation and function of the related elements of the structure, to various details of construction and to combinations of parts, elements per se, and to economies of manufacture and numerous other features as will be apparent from a consideration of the specification and drawing of a form of the invention, which may be preferred, in which:

FIGURE 1 is an isometric view of a gear housing component fashioned of sheet metal in inverted position illustrating solid inserts permanently assembled through the use of the method of the invention;

FIGURE 2 is an isometric view of the gear housing component of FIGURE 1 shown in upright position;

FIGURE 3 illustrates a preformed configuration of a sheet metal body in preparation for assembly with a solid insert;

FIGURE 4 is a vertical sectional view illustrating the interlocking relationship of the sheet metal with the insert after assembly by the method of the invention;

FIGURE 5 is a transverse sectional view taken substantially on the line 55 of FIGURE 4;

FIGURE 6 is a vertical sectional view illustrating an apparatus for carrying out the method of the invention in assembling a single insert with a sheet metal body;

FIGURE 7 is a schematic sectional view illustrating the method of shaping a sheet metal body to embrace a plurality of solid inserts disposed in spaced relation;

FIGURE 8 is a sectional view illustrating another form of insert of nonci-rcular cross section embraced by a sheet metal body, and

FIGURE 9 is a view similar to FIGURE 6 illustrating the method of assembling a modified form of insert with a sheet metal body.

While the method of the invention is illustrated in forming a sheet of metal to provide a gear housing construction with solid metal inserts anchored in the sheet metal body through the use of the method of the invention, it is to be understood that the method of the inven tion may be utilized wherever it is desirable to fixedly anchor or permanently secure inserts for various purposes to a sheet metal body.

Referring to FIGURES l and 2, there is illustrated a product or construction made in accordance with the method of the invention, the product being a gear housing or housing component 10 fashioned of sheet metal having a panel portion 12, side wall regions 14 and a peripheral or marginal flange 16, these portions being integral configurations of a single sheet of metal such as sheet steel. In the gear housing illustrated in FIGURES 1 and 2, a raised hollow portion 18 is fashioned integral with the panel portion 12 and disposed above and integral with the raised portion 18 is a hollow boss portion 20 of smaller cross section than that of the portion 18.

Formed integral with and extending upwardly from the panel portion 12 are hollow boss portions 22 and 24, the hollow boss portions 20, 22 and 24 embracing or enclosing solid inserts 26 of the character shown in FIGURE 4. The inserts 26 are assembled within and anchored or permanently secured to the sheet metal boss portions through the utilization of the method hereinafter described. The bosses 20, 22 and 24 are preferably reinforced by webs 25 formed of the sheet metal of the body.

Each insert 26, particularly shown in FIGURES 4 and 5, is of metal and is solid except for a central bore 28 which, in the gear housing construction illustrated, forms bearing means for a shaft (not shown).

The inserts 26 may be fashioned of cast iron, bronze or other metal depending upon the purposes for which they are used. Each insert 26, in the form shown in FIG- UR'ES 4 and 5, is fashioned with indentations such as lengthwise spaced circumferential recesses 30 preformed in the insert 26, the bore' 28 being formed in the insert before assembly with the sheet metal to form the housing. As shown in FIGURE 5, the peripheral region of the insert 26 is fashioned with a planar portion 32 which serves, in assembly with the sheet metal housing, to prevent relative rotation of the insert.

In forming, drawing or shaping the sheet metal to embrace or surround the insert 26, the metal of the sheet is cold flowed into the peripheral recesses 30 providing ridges or projections 34 which engage and interlock in the recesses 30 to prevent lengthwise movement of the insert 26 with respect to the sheet metal embracing the insert. Through the peripheral noncircular shape provided by the flat or planar surface 32 on the insert 26 and the ridges 34 established by metal forced into the peripheral recesses 30 when the insert is assembled with the sheet metal, the insert is permanently anchored in the sheet metal boss portion. Each insert 26 may be of the desired dimension having a bore 28 to accommodate a shaft of a size depending upon the mechanism to be enclosed within the housing 10.

The method of the invention is carried out by a die set for shaping the sheet metal to embrace the inserts. FIGURE 3 illustrates a metal sheet A which is preferably preformed with a dished or concave portion 40 at the region of the insert to be embraced by the sheet metal. FIGURE 6 illustrates a die set arrangement for configurating or shaping a metal sheet to embrace a single insert 26. The die set for carrying out the method of the invention, as illustrated in FIGURE 6, includes a base plate or bolster 44 mounted upon a suitable support or bed of a press (not shown), a vertically reciprocable press ram 46 carrying a die 48 fashioned with a recess 50.

The die set includes a stripper plate 52 supported on the base plate 44 by a plurality of expansive coil springs 54 in a conventional manner. The bolster or base plate 44 supports a guide pin or post 56, the upper end of which is adapted to be snugly, yet slidably received in the bore 28 of the insert 26 to properly position the insert 26, the axis of the guide pin 56 and the insert 26 being aligned with the axis of the recess or cavity 50 in the die 48.

In the use of the die arrangement shown in FIGURE 6, the sheet metal plate A, preconfigurated with the concave portion 40, is disposed with the concave portion adjacent the insert 26 in the position shown in FIGURE 6. The transverse dimension of the recess 50 is approximately equal to the transverse dimension of the insert 26 and double thickness of the metal of the plate A.

With the components of the die set and the plate A in the position shown in FIGURE 6, the press ram 46 is moved downwardly by conventional mechanism to engage the interior wall regions 51 of the recess 50 with the sheet metal plate A at the regions of the upper peripheral edge of the insert 26.

As the cavity die 48 is progressively moved downwardly by the press ram 46, the metal of plate A is shaped, configurated and drawn into contiguous embracing or surrounding relation with the peripheral surface regions of the insert 26. As the metal of the sheet or plate A is progressively drawn by the die 48 along the peripheral surface of the insert 26, the metal of the sheet is forced or cold-flowed into the recesses 30, the metal occupying the recesses in the form of inwardly extending ridges 34, shown in FIGURE 4.

During downward movement of the ram 46 and die 48, the face portion 49 of the die 48 engages the metal of the sheet A adjacent the stripper plate and moves the stripper plate, the insert 26 and the sheet metal downwardly, compressing the springs 54, the springs providing substantial resistance to the portion of the sheet A being moved into contiguous relation with the stripper plate 52 at the lowermost position of the die 48. When the die 48 reaches its lowermost or fully closed position, the insert 26 is embraced or surrounded by the metal of the plate A which has been shaped and drawn into the position shown in FIGURE 4.

Through this method the flattened portion 58 of the boss portion 22, shown in FIGURE 5, fashioned by the die operation, engages the flat surface 32 of the insert 26, and the inwardly extending ridges 34 interlock in the recesses 30, providing means securely anchoring the insert in the sheet metal body. Upon upward movement or withdrawal of the ram 46 and the die 48, the stripper plate 52, under the influence of the pressure of the compressed springs 54, moves upwardly to strip the formed body and insert construction or assembly upwardly of the pins 56 to facilitate removal of the plate and insert construction from the pins.

FIGURE 7 illustrates the method of the invention for concomitantly aflixing inserts in the boss portions 20, 22 and 24 of the metal sheet or plate A utilized for forming the gear housing shown in FIGURES 1 and 2, the section of FIGURE 7 being expanded to illustrate the three inserts 26 in a single vertical plane. The die set shown in FIGURE 7 includes a base or bolster plate 60, a vertically reciprocable ram 62 of a conventional press construction, and forming rings or dies 64, 66 and 68 carried by the ram 62, The dies 64 and 68 are provided with recesses or cavities 70 and the die 66 provided with a recess or cavity 72 and a counter recess 74. The recesses 70 are of transverse dimensions to fashion the sheet metal bosses 22 and 24 of the construction shown in FIGURE 2, and the recess 72 of a dimension to fashion the boss 20.

The counter recess 74 is of a transverse dimension to fashion the raised sheet metal portion 18, shown in FIGURES 1 and 2. The metal sheet A, preconfigurated with the curved or dished portions such as illustrated at 40 in FIGURE 3, is disposed in the position illustrated in FIGURE 7 with intermediate regions adjacent the stripper plate 76, the latter being mounted upon coil springs 78 normally holding the stripper plate in its uppermost or normal position.

Supported upon the stripper plate 76 and disposed in alignment with and beneath the counter recess 74 is a male die member or block 80 of a height to form the raised portion 18 of the gear housing shown in FIGURES 1 and 2. One of the inserts 26 is initially supported by the die block 80 and is maintained in aligned relation with the cavity 72 of the die member 66 by the guide portion 82 of a guide pin 84 carried by the base plate or bolster 60, the guide portion 82 being snugly, yet slidably received in the bore 28 of the insert. The other two inserts 26, shown in FIGURE 7, are located or disposed in alignment with the die cavities 70 by guide pins 86 carried by the bolster 60, the guide pins adapted to be snugly, yet slidably received in the bores 28 in the inserts.

With the preformed metal sheet A in the position shown in FIGURE 7, the ram 62 and the cavity dies 64, 66 and 68 are moved downwardly into engagement with the sheet metal A.

As the dies move downwardly, the metal of the sheet adjacent the inserts 26 is forced, distorted and drawn into snug engagement with the peripheral surface configurations of the inserts 26, the progressive drawing action of the dies forcing the metal of the sheet into the peripheral recesses or indentations 30 in the inserts establishing the ridges of metal 34, shown in FIGURE 4, to permanently anchor or secure the inserts in the hollow bosses formed by the drawing operation.

Under the influence of the shapes of the die cavities 70 and 72, each having a planar surface reciprocal to the planar surface 32 on each insert, the metal of the sheet is fashioned to form the flat portion, such as shown at 58in FIGURE 5. The ram 62 and dies carried thereby move to .a lowermost orfullyclosed position, compressing the springs 78. Upon retraction or upward movement of the ram-62 and the dies carried thereby, the compressed spring 78 moves thest'ripper plate 76- upwardly to the position shown ;in, FIGURE 7, facilitating removal of the assembly of metal sheet and inserts.

I Through the cold-flowing of the metal of the sheet into the indentations or recesses 30 in the inserts and the fashioning of the planar portion 58 in engagement with the planar surface32 of each insert, the inserts are permanently anchoredor secured against movement relative to the metal sheet'li The metal ridges 34 prevent relative lengthwise movement and the flat portion 58 prevent rotational movement of the inserts.

The reinforcing web's 25, shown in FIGURE 2, may be concomitantly formed by'the method step illustrated in FIGURE 7. The stripper plate 76 supports projections (not shown')'"reciprocal in shape to the webs 25 and the die's64, 66 and 6ti'fashionedwith slots (not shown) to accommodate the projections and adjacent sheet metal to form the webs 25 during downward movement of the ram carrying the dies 64, 66 and 68.

FIGURE 8 is a sectional view illustrating a modified shape of insert. In this form the insert 26 is of oval configuration and is fashioned with one or more peripheral recesses 30' into which the metal of the sheet at the boss portion 22' is forced or cold flowed into the recesses or indentations. In the form shown in FIGURE 8, the oval or noncircular shape of the insert 26' together with the metal forced into the recesses 30' permanently anchors the insert within the boss portion formed on the metal sheet preventing any relative movement between these components. The insert 26' is formed with a central bore 28 i It is to be understood that the inserts 26 or 26' may may be fashioned with other noncircular cross sectional shapes to prevent relative rotation of the inserts.

FIGURE 9 illustrates the method of the invention utilized in securing a modified form of insert to a sheet metal body. In this form the insert 90 of noncircular cross section, which may be of a cross-sectional configuration shown in FIGURE or FIGURE 8, is provided with peripheral recesses or indentations 92 of the character shown at 30 in FIGURE 4.

The insert 90 is fashioned with an integral projecting tenon or shaft portion 94 which, in use, may be employed as journal means for a rotatable member.

The base member or bolster 100- is fashioned with a boss portion 96 provided with a bore 98 of a dimension to slidably receive the tenon or shaft portion 94 of the insert to provide a guide and positioning means for the insert in the manner shown in FIGURE 9. In assembling the insert 90 with a sheet metal body A", the body is preformed with a curved portion 40" and the body disposed above the stripper plate 102 with the curved portion 40 adjacent the upper region of the insert 90. The stripper plate is supported by coil springs 54".

A die 48 carried by a ram 46" is provided with a cavity 50". Upon downward movement of the press ram 46 the wall defining the cavity is moved into overlapping relation with the insert 90, forcing the metal of the sheet A in snug contiguous relation with the peripheral surface area of the insert 90 and the metal of the sheet cold flowed into the peripheral recesses 92 for permanently anchoring or securing the insert in the sheet metal body.

It is to be understood that the form of insert 90 shown in FIGURE 9 may be one of a plurality of inserts to be afiixed in a sheet metal body in the manner and through the arrangement shown in FIGURE 7.

It is apparent that, within the scope of the invention, modifications and different arrangements may be made other than as herein disclosed, and the present disclosure is illustrative merely, the invention comprehending all variations thereof.

We claim:

1. The method of assembling an insert having an indentation in a peripheral surface with a' sheet metal body including disposing the insert in engagement with a guide surface, preforming a portion of the sheet metal body with a dished configuration, positioning the sheet metal body with the dished configuration adjacent the insert, engaging a cavity die with the metal body, forcing the die toward and in overlapping relation with the insert to cold flow the metal of the sheet along the peripheral surface of the insert into the identation and in snug contiguous embracing relation with the peripheral surface of the insert whereby to permanently secure the insert within the region of the sheet metal body occupied by the insert.

2. The method of assembling an insert of noncircular cross section having a recess with a sheet metal body including disposing the insert on a support in engagement with a guide surface, preforming a portion of the sheet metal body with a dished configuration, positioning the sheet metal body with the dished configuration adjacent the insert, engaging a cavity die with the metal body, forcing the die toward and in overlapping relation with the insert to cold flow the metal of the sheet along the peripheral surface of the insert and into the recess and in snug contiguous embracing relation with the peripheral surface of the insert whereby to permanently anchor the insert within the region of the sheet metal body occupied by the insert.

3. The method of assembling an insert of noncircular cross section having a peripheral recess spaced from the ends of the insert including preforming a portion of a 'metal sheet with dished configuration, disposing the sheet of metal with the dished configuration adjacent the insert, engaging a cavity die with the sheet of metal, forcing the die toward and in overlapping relation with the insert with the sheet metal between the die and the insert to cold flow the sheet metal along the insert into the recess and in snug embracing relation with exterior surface areas of the insert whereby to permanently anchor the insert within the embracing portion of the metal sheet.

4. The method of assembling an insert of noncircular cross section having a peripheral groove spaced from the ends of the insert including preforming a portion of a sheet metal body with a dished configuration, disposing the sheet of metal with the dished configuration adjacent the insert, engaging the sheet of metal with a cavity die, forcing the die toward the insert with the metal of the sheet between the die and the insert to cold flow the metal of the sheet along the insert into the groove and in snug embracing relation with exterior surface areas of the insert whereby to permanently anchor the insert within the embracing portion of the metal sheet.

5. The method of concomitantly assembling a plurality of inserts with a sheet metal body wherein each insert is of noncircular cross section and has a peripheral indentation therein including preforming dished configurations in the sheet metal body, disposing the inserts in spaced relation in engagement with guide surfaces to position the inserts, disposing the sheet metal body with the dished configurations adjacent the inserts, engaging the sheet metal body with a cavity die, forcing the die and sheet metal body toward and in overlapping relation with the inserts to embrace the inserts by the sheet metal and cold flow the metal into the peripheral indentations 'and the sheet metal configurated into snug contiguous engagement with peripheral surfaces of the inserts to permanently anchor the inserts to the sheet metal 'body.

'6. The method of assembling an insert having a central bore and a recess in an exterior surface with a sheet metal body including preforming a curved region in the sheet metal body, disposing the insert on a guide surface extending into the bore in the insert, disposing the sheet metal body with the preformed curved region adjacent the insert, engaging a cavity die with the sheet metal body,

forcing the die and sheet metal body toward and in overlapping relationship with the insert to embrace the insert by the sheet metal body and cold flow the metal of the body into the recess whereby the sheet metal is configurated into snug contiguous engagement with the peripheral surface of the insert to permanently anchor the insert to the sheet metal body.

7. The method of concomitantly assembling a plurality of inserts with a sheet metal body and each insert having a peripheral recess including preforming curved regions in the sheet metal body, disposing the inserts in spaced relation on a support in engagement with guide surfaces to position the inserts, disposing the sheet metal with the preformed curved regions adjacent the respective inserts, engaging the sheet metal body with a cavity die, forcing the die and sheet metal body toward and in overlapping relation with the inserts to embrace the inserts by the sheet metal and cold flow the metal into the peripheral recesses whereby the sheet metal is configurated into snug contiguous engagement with peripheral surfaces of the inserts to permanently anchor the inserts to the sheet metal body.

8. The method of concomitantly assembling a plurality of inserts with a sheet metal body, each insert being of noncircular cross section with a peripheral recess therein including preforming curved regions in the sheet metal body at the regions to be occupied by the inserts, disposing the inserts inspaced relation in engagement with guide surfaces to position the inserts, disposing th'e preformed sheet metal body adjacent the inserts, engaging the sheet metal body with a cavity die, forcing .the die and sheet metal body toward the inserts to embrace the" inserts by the sheet metal and cold flow the metal into the recesses whereby the sheet metal is configurated into snug contiguous engagement with the peripheral surfaces of the inserts to permanently anchor the inserts to the sheet metal body.

References Cited UNITED STATES PATENTS 1,006,263 10/ 1911 OLeary. 1,334,051 3/1920 Prime. 1,348,967 8/ 1920 Sommers. 1,580,186 4/1926 Wiley. p 2,456,506 12/1948 Henchert. f I 3,098,681 7/1963 Kohlhagen et a1. 74-606 X 3,121,944 2/ 1964 Karau 2952 0 X 3,224,789 12/1965 Tessler et a1. 16-31 X FOREIGN PATENTS 921,090 4/1947 France.

CHARLIE T. MOON, Primary Examiner. 

1. THE METHOD OF ASSEMBLING AN INSERT HAVING AN INDENTATION IN A PERIPHERAL SURFACE WITH A SHEET METAL BODY INCLUDING DISPOSING THE INSERT IN ENGAGEMENT WITH A GUIDE SURFACE, PREFORMING A PORTION OF THE SHEET METAL BODY WITH A DISHED CONFIGURATION, POSITIONING THE SHEET METAL BODY WITH THE DISHED CONFIGURATION ADJACENT THE INSERT, ENGAGING A CAVITY DIE WITH THE METAL BODY, FORCING THE DIE TOWARD AND IN OVERLAPPING RELATION WITH THE INSERT TO COLD FLOW THE METAL OF THE SHEET ALONG THE PERIPHERAL SURFACE OF THE INSERT INTO THE IDENTATION AND IN SNUG CONTIGUOUS EMBRACING RELATION WITH THE PERIPHERAL SURFACE OF THE INSERT WHEREBY TO PERMANENTLY SECURE THE INSERT WITHIN THE REGION OF THE SHEET METAL BODY OCCUIPED BY THE INSERT. 